U.S. patent number 9,269,967 [Application Number 13/700,578] was granted by the patent office on 2016-02-23 for gasket.
This patent grant is currently assigned to NOK Corporation. The grantee listed for this patent is Shotaro Koga, Yoshihiro Kurano, Takeshi Masaka. Invention is credited to Shotaro Koga, Yoshihiro Kurano, Takeshi Masaka.
United States Patent |
9,269,967 |
Masaka , et al. |
February 23, 2016 |
Gasket
Abstract
Provided is a gasket which can improve a handling property of
the gasket by enhancing a rigidity of a carrier, can secure a space
saving without increasing a thickness of the gasket, and can
improve a yield ratio of a resin material, in the gasket of a type
that a gasket body is integrated with the resin carrier. A planar
gasket used by being pinched between two members superposed with
each other has a gasket body achieving a seal action, and a carrier
retaining the gasket body, the carrier is formed as a predetermined
planar shape by a metal mold with a resin material, and is formed
as a stepped shape by setting a partial portion which is superposed
with the gasket body on a plane to a thin portion, and setting the
other portion which is not superposed with the gasket body on the
plane to a thick portion.
Inventors: |
Masaka; Takeshi (Fujisawa,
JP), Kurano; Yoshihiro (Fujisawa, JP),
Koga; Shotaro (Fujisawa, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
Masaka; Takeshi
Kurano; Yoshihiro
Koga; Shotaro |
Fujisawa
Fujisawa
Fujisawa |
N/A
N/A
N/A |
JP
JP
JP |
|
|
Assignee: |
NOK Corporation
(JP)
|
Family
ID: |
45348033 |
Appl.
No.: |
13/700,578 |
Filed: |
May 26, 2011 |
PCT
Filed: |
May 26, 2011 |
PCT No.: |
PCT/JP2011/062047 |
371(c)(1),(2),(4) Date: |
November 28, 2012 |
PCT
Pub. No.: |
WO2011/158624 |
PCT
Pub. Date: |
December 22, 2011 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20130065158 A1 |
Mar 14, 2013 |
|
Foreign Application Priority Data
|
|
|
|
|
Jun 14, 2010 [JP] |
|
|
2010-134784 |
Aug 25, 2010 [JP] |
|
|
2010-187844 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16J
15/104 (20130101); H01M 8/0286 (20130101); H01M
8/0276 (20130101); H01M 8/0273 (20130101); H01M
8/0271 (20130101); Y02E 60/50 (20130101) |
Current International
Class: |
H01M
8/02 (20060101); F16J 15/10 (20060101); H01M
2/08 (20060101) |
Field of
Search: |
;429/516,507-511
;277/644 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2058883 |
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May 2009 |
|
EP |
|
2002228001 |
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Aug 2002 |
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JP |
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2004245341 |
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Sep 2004 |
|
JP |
|
2005226692 |
|
Aug 2005 |
|
JP |
|
2006210234 |
|
Aug 2006 |
|
JP |
|
2008218287 |
|
Sep 2008 |
|
JP |
|
2009049025 |
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Mar 2009 |
|
JP |
|
2010112401 |
|
May 2010 |
|
JP |
|
WO-2008129840 |
|
Oct 2008 |
|
WO |
|
Primary Examiner: Fraser; Stewart
Attorney, Agent or Firm: Harness, Dickey & Pierce,
P.L.C.
Claims
What is claimed is:
1. A planar gasket adapted to be pinched between two members which
are superposed with each other, the gasket comprising: a gasket
body which forms a seal between the two members; and a carrier
which retains said gasket body, wherein said carrier is formed to a
predetermined planar shape by a metal mold with a resin material,
and has a stepped shape including: a thin partial portion which is
superposed with said gasket body on a plane, and a thick portion
which is not superposed with said gasket body on the plane, and
wherein said gasket body has a C-shaped superposed portion which is
superposed with said thin partial portion of said carrier on the
plane and a non-superposed portion which is not superposed with
said thin partial portion, and a pair of seal lips oppositely
extend from the superposed portion, and the thin partial portion
has a thickness t1, the thick portion has a thickness t2, the
superposed portion has a thickness t3, and a thickness between
leading ends of the pair of seal lips is t5, t3=t2, t3>t1, and
t5>t3, wherein said gasket body and said carrier are provided
with a retaining structure for preventing said gasket body and said
carrier from coming off from each other, and wherein said retaining
structure is constructed by and engagement of said gasket body with
a three-dimensional shape selected from a group including a convex
portion, a concave portion or a through hole which is provided in
said carrier.
2. The gasket as claimed in claim 1, wherein said gasket body is
formed by injection molding a non-adhesive rubber after applying an
adhesive agent to said carrier, or by injection molding an adhesive
rubber without applying any adhesive agent to said carrier.
3. The gasket as claimed in claim 2, wherein said gasket is a
gasket for a fuel battery which is embedded in a fuel battery stack
or cell.
4. The gasket as claimed in claim 1, wherein said gasket body is
formed by injection molding a non-adhesive rubber without applying
any adhesive agent to said carrier.
5. The gasket as claimed in claim 4, wherein said gasket is a
gasket for a fuel battery which is embedded in a fuel battery stack
or cell.
6. The gasket as claimed in claim 1, wherein said gasket is a
gasket for a fuel battery which is embedded in a fuel battery stack
or cell.
7. The gasket as claimed in claim 1, wherein said retaining
structure further comprises a concave portion provided in both
surfaces in a thickness direction of said thin partial portion and
part of the superposed portion of the gasket body is filled in the
concave portion.
8. The gasket as claimed in claim 1, wherein said retaining
structure for preventing said gasket body and said carrier from
coming off from each other is provided along said superposed
portion.
9. The gasket as claimed in claim 1, wherein said retaining
structure for preventing said gasket body and said carrier from
coming off from each other is provided along said non-superposed
portion.
10. The gasket as claimed in claim 1, wherein said retaining
structure for preventing said gasket body and said carrier from
coming off from each other is provided so as to pan from said
superposed portion to said non-superposed portion.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage Application of
International Application No. PCT/JP2011/062047, filed on May 26,
2011 and published in Japanese as WO 2011/158624 on Dec. 22, 2011.
This application claims the benefit of Japanese Application Nos.
2010-134784, filed on Jun. 14, 2010 and 2010-187844, filed on Aug.
25, 2010. The entire disclosures of the above applications are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a gasket in accordance with a seal
technique. The gasket in accordance with the present invention is
used, for example, as a gasket for a fuel battery, or as the other
general gasket.
2. Description of the Conventional Art
For example, for a popularization of a fuel battery in the future,
there is demanded an improvement of a productivity as well as a low
cost of a gasket and an improvement of a handling property for that
purpose (a provision of a certain degree of rigidity in a planar
gasket and an easy handling thereof, for example, an easy gripping
thereof by a chuck apparatus).
A plate integral type gasket (in which a plate is constructed, for
example, by a separator of a fuel battery cell and the plate is a
constructing part of a fuel battery main body) which is a prior
art, has an advantage that a handling property is improved, since
the gasket is retained by the plate and the rigidity is increased
at that degree, in comparison with a rubber only type gasket (R/O).
However, it is necessary to take into consideration a replacement
of the gasket at a time of popularizing the fuel battery, and since
the plate integrated type gasket is the integrated product, it is
necessary to replace the plate in addition to the replacement of
the gasket.
In this regard, in the R/O, it is sufficient to replace only the
gasket, however, since the rigidity is low in the rubber only,
there is the problem that the handling property is not good as
mentioned above.
Further, in order to improve the R/O handling property, there can
be thought that the gasket is integrated with a carrier which is
constructed by a resin film (the carrier is an exclusive gasket
constructing part which retains the gasket and is not a
constructing part of the fuel battery main body) as described in
the following patent document 1, however, since the resin film
generally has a thin thickness (for example, about 3 mm) and can
not be said to have a sufficiently high rigidity, it is demanded to
further increase the rigidity and improve a handling property
thereby.
Further, in the case that a ready-made resin film is used as the
carrier as mentioned above, it is used after cutting a considerable
area portion of the resin film (drawing off the film) in connection
with a provision of a space portion which passes through in a
thickness direction within a gasket plane. Accordingly, there is a
disadvantage that a yield ratio is not good with regard to the
film, and further with regard to the resin material.
SUMMARY OF THE INVENTION
Problem to be Solved by the Invention
The present invention is made by taking the point mentioned above
into consideration, and an object of the present invention is to
provide a gasket which can improve a handling property of the
gasket by further enhancing a rigidity of a carrier, can secure a
space saving without increasing a thickness of the gasket, and can
improve a yield ratio of a resin material, in the gasket of a type
that a gasket (a gasket body) made of a rubber-like elastic
material is integrated with the carrier made of a resin.
Further, in addition to the above mentioned advantages, an object
of the present invention is to provide a gasket which can be easily
manufactured by omitting a bonding step from a manufacturing
process, in the gasket of the type that the gasket (the gasket
body) made of the rubber-like elastic material is integrated with
the carrier made of the resin.
Means for Solving the Problem
In order to achieve the object mentioned above, a gasket in
accordance with a first aspect of the present invention is a planar
gasket which is used by being pinched between two members (for
example, a separator in a fuel battery cell and an MEA as the two
members) which are superposed with each other, the gasket
comprising:
a gasket body which achieves a seal action; and
a carrier which retains the gasket body,
wherein the carrier is formed as a predetermined planar shape by a
metal mold with a resin material, and is formed as a stepped shape
by setting a partial portion which is superposed with the gasket
body on a plane to a thin portion, and setting the other portion
which is not superposed with the gasket body on the plane to a
thick portion.
Further, a gasket in accordance with a second aspect of the present
invention is the gasket described in the first aspect mentioned
above, wherein the gasket body has a portion which is superposed
with the thin portion in the carrier on the plane and a portion
which is not superposed therewith, and a seal lip is provided at
the latter position which is not superposed among them.
Further, a gasket in accordance with a third aspect of the present
invention is the gasket described in the first aspect mentioned
above, wherein the gasket body has a portion which is superposed
with the thin portion in the carrier on the plane and a portion
which is not superposed therewith, and a seal lip is provided at
the former portion which is superposed among them.
Further, a gasket in accordance with a fourth aspect of the present
invention is the gasket described in any one of the first to third
aspects mentioned above, wherein the gasket body is formed by
injection molding a non-adhesive rubber after applying an adhesive
agent to the carrier, or by injection molding an adhesive rubber
without applying any adhesive agent to the carrier.
Further, a gasket in accordance with a fifth aspect of the present
invention is the gasket described in any one of the first to third
aspects mentioned above, wherein the gasket body is formed by
injection molding a non-adhesive rubber without applying any
adhesive agent to the carrier, and the gasket body and the carrier
are provided with a retaining structure for preventing the both
from coming off from each other.
Further, a gasket in accordance with a sixth aspect of the present
invention is the gasket described in the fifth aspect mentioned
above, wherein the retaining structure is constructed by an
engagement of the gasket body with a three-dimensional shape such
as a convex portion, a concave portion or a through hole which is
provided in the carrier.
Further, a gasket in accordance with a seventh aspect of the
present invention is the gasket described in any one of the first
to sixth aspects mentioned above, wherein the gasket is a gasket
for a fuel battery which is embedded in a fuel battery stack or
cell.
The prior art in which the gasket is integrated with the carrier
constructed by the resin film has room for improvement in the
handling property thereof, since the resin film is fixed in its
thickness dimension over a whole surface, and does not have any
portion which particularly secures the rigidity. On the contrary,
in the present invention, since the carrier is formed as the
predetermined planar shape by the metal mold with the resin
material, and is formed as the stepped shape having the different
thicknesses, by setting the partial portion which is superposed
with the gasket body on the plane to the thin portion, and setting
the other portion which is not superposed with the gasket body on
the plane to the thin portion, it is possible to secure a
sufficient rigidity by the thick portion among them.
Further, since it is structured such that the gasket body is
superposed and integrated with the thin portion in place of the
thick portion in the carrier on the plane, it is possible to secure
a space saving in the gasket thickness direction without increasing
the thickness as a whole of the gasket, and since the carrier is
formed by the metal mold with the resin material, the carrier is
originally formed as a product shape and does not have any portion
to be cut. Therefore, it is possible to improve a yield ratio of
the resin material.
In the case that both the thick portion and the thin portion are
formed in one planar carrier, there can be thought a pattern that
the thin portion is arranged in the center in the thickness
direction of the thick portion or approximately the center, and a
pattern that the thin portion is arranged so as to be biased to one
side in the thickness direction of the thick portion, as a
positional relationship in the thickness direction of the thin
portion with respect to the thick portion. Further, in the case of
the former pattern, a stepped shape is formed in each of both
surfaces in the carrier thickness direction, and in the case of the
latter pattern, a stepped shape is formed only in one surface in
the thickness direction of the carrier (in this case, the thick
portion and the thin portion are formed as the same planar shape (a
flush shape) in a surface in an opposite side), however, both the
patterns are included in the present invention.
Further, as the gasket body, it is general to be provided with a
seal lip for enhancing a seal surface pressure, however, with
regard to an arrangement of the seal lip, there can be thought a
pattern that it is provided at a portion which is not superposed
with the thin portion of the carrier on the plane (the second
aspect), and a pattern that it is provided at a portion which is
superposed with the thin portion of the carrier on the plane (the
third aspect), and both the patterns are included in the present
invention.
Further, the gasket body is formed by a predetermined rubber-like
elastic body, and in more detail, is frequently formed by injection
molding the non-adhesive rubber after applying the adhesive agent
to the carrier, or by injection molding the adhesive rubber without
applying the adhesive agent to the carrier (in this case, an
adhesion property which the adhesive rubber is provided itself is
utilized for the adhesion) (the fourth aspect), however, in these
cases, in the gasket manufacturing process, a bonding step for
bonding the gasket body to the carrier is necessary. On the
contrary, if the bonding step can be omitted, the manufacturing of
the gasket can be made easier at that degree.
Accordingly, in order to omit the bonding step as mentioned above,
it is structured such that the gasket body is formed by injection
molding the non-adhesive rubber without applying the adhesive agent
to the carrier, and the gasket body and the carrier are provided
with the retaining structure for preventing both the elements from
coming off from each other (the fifth aspect), in place of the
adhesion. As the retaining structure, it is preferable that the
carrier is provided with an engagement portion which is constructed
by the three-dimensional shape such as the convex portion, the
concave portion or the through hole, and the gasket body is engaged
with the engagement portion (the sixth aspect).
Further, in the case that the gasket in accordance with the present
invention is used as the gasket for the fuel battery, the gasket
for the fuel battery is provided with a portion which seals a
peripheral edge portion of a reaction surface in the fuel battery
cell (a reaction surface seal portion) or a position which seals a
peripheral edge portion of a manifold (a manifold seal portion) for
preventing a fuel gas or the like from leaking. Accordingly, the
thin portion of the carrier and the gasket body are arranged in the
seal portion (the seventh aspect).
Effect of the Invention
As described above, in accordance with the present invention, since
the carrier is formed as the predetermined planar shape by the
metal mold with the resin material, and is also formed as the
stepped shape in which the partial portion which is superposed with
the gasket body on the plane is set to the thin portion, and the
other portion which is not superposed with the gasket body in the
plane is set to the thick portion, it is possible to secure a
sufficient rigidity by the thick portion among them, and it is
possible to further improve a handling property of the gasket in
connection with the sufficient rigidity. Further, since the gasket
body is structured such as to be superposed with the thin portion
of the carrier on the plane, the thickness as a whole of the gasket
is not increased, and it is possible to secure a space saving.
Further, since it is structured such that the carrier is formed by
the metal mold with the resin material, the carrier is formed as
the product shape from the beginning, and it is accordingly
possible to improve a yield ratio of the resin material.
Further, in the case that the gasket body is formed by injection
molding the non-adhesive rubber without applying the adhesive agent
to the carrier, and the gasket body and the carrier are provided
with the retaining structure for preventing both the elements from
coming off from each other in place of the adhesion, it is possible
to omit the bonding step from the gasket manufacturing process, and
it is accordingly possible to make the manufacturing of the gasket
easier at that degree.
Further, in the case that the gasket in accordance with the present
invention is used as the gasket for the fuel battery, the effects
mentioned above can be obtained in the gasket for the fuel
battery.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1A is a general plan view of a carrier in a gasket in
accordance with a comparative example;
FIG. 1B is an enlarged cross sectional view along a line C-C in
FIG. 1A;
FIG. 2 is a cross sectional view of a substantial part of the
gasket in accordance with the comparative example;
FIG. 3 is a cross sectional view of a substantial part of a gasket
in accordance with the other comparative example;
FIG. 4 is a cross sectional view of a substantial part of a gasket
in accordance with the other comparative example;
FIG. 5A is a general plan view of a carrier in a gasket in
accordance with a first embodiment of the present invention;
FIG. 5B is an enlarged cross sectional view along a line D-D in
FIG. 5A;
FIG. 6 is a cross sectional view of a substantial part of the
gasket in accordance with the first embodiment of the present
invention;
FIG. 7 is a cross sectional view of a substantial part of a gasket
in accordance with a second embodiment of the present
invention;
FIG. 8 is a cross sectional view of a substantial part of a gasket
in accordance with a third embodiment of the present invention;
FIG. 9 is a cross sectional view of a substantial part of the
gasket in accordance with the embodiment, and is an enlarged cross
sectional view along a line E-E in FIG. 8;
FIG. 10 is a cross sectional view of a substantial part of a gasket
in accordance with a fourth embodiment of the present
invention;
FIG. 11 is a cross sectional view of a substantial part of a gasket
in accordance with a fifth embodiment of the present invention;
FIG. 12 is a cross sectional view of a substantial part of a gasket
in accordance with a sixth embodiment of the present invention;
FIG. 13 is a cross sectional view of a substantial part of a gasket
in accordance with a seventh embodiment of the present
invention;
FIG. 14 is a cross sectional view of a substantial part of a gasket
in accordance with an eighth embodiment of the present
invention;
FIG. 15 is a cross sectional view of a substantial part of a gasket
in accordance with a ninth embodiment of the present invention;
FIG. 16 is a cross sectional view of a substantial part of a gasket
in accordance with a tenth embodiment of the present invention;
FIG. 17 is a cross sectional view of a substantial part of a gasket
in accordance with an eleventh embodiment of the present invention;
and
FIG. 18 is a cross sectional view of a substantial part of a gasket
in accordance with a twelfth embodiment of the present
invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following embodiments are included in the present
invention.
(1) A low cost can be expected on the basis of a frame
manufacturing construction method by molding, by setting a carrier
member to a resin frame. Further, it is possible to maintain a
rigidity of the frame and downsize a gasket by forming a cross
section as a stepped shape. The resin frame is a molded product by
a metal mold, and is not a resin film which is obtained by a roll
forming.
(2) As an effect, it is possible to achieve a cost reduction on the
basis of an automation from a gasket producing step to a stack
assembly, by improving a rigidity of the gasket, and a cost
reduction of the carrier member on the basis of a resin molding of
a rigid body.
(3) For example, a cross sectional view in which a gasket (a gasket
body) is integrated with a carrier member (a carrier) in FIG. 1 is
shown in FIG. 2, FIG. 3 and FIG. 4. FIG. 2 shows a structure in
which a seal lip is arranged outside the carrier, and a space
saving at a time of assembling is expected. FIG. 3 shows a
structure in which the seal lip is arranged on the carrier, and a
rigidity keeping is expected in comparison with FIG. 2. While FIG.
2 and FIG. 3 employs an injection molding by applying an adhesive
agent as a rubber material, or an adhesive rubber, FIG. 4 shows a
structure in which a bonding process is omitted for the purpose of
doing away with the bonding step, and a gasket forming portion is
provided with a retaining portion which is constructed by a
concavity and convexity or a through hole (a convex portion in the
drawing) in place of the adhesive method. However, since the
carrier member in FIG. 1 is formed as a thin planar shape (a
quadrangular cross sectional shape), it is necessary to increase a
thickness taking a rigidity into consideration. A carrier member in
FIG. 5 is formed as a cross sectional shape which solves the
problem, and is formed such that only a gasket forming portion is
thin and the other portion is thick. A cross sectional view of a
structure in which the gasket is integrated with the carrier member
in FIG. 5 is shown in FIG. 6 and FIG. 7 and after. An effect of the
gasket is the same as mentioned above, however, since only the
gasket forming portion is thin, a space saving at a time of
assembling is expected.
(4) The present invention relates to a structure (a cross sectional
shape) of a reinforcing body for the purpose of improving a
handling property in a reinforcing body (a carrier) integrated
gasket. In order to solve the problem of the handling property in
the R/O as a structure of the gasket for the fuel battery, it is
generally carried out to integrally form the gasket in the
reinforcing body such as a resin film or the like. In the case of
the film integrated gasket, an improvement of the handling property
can be achieved in comparison with the R/O type, however, since a
thickness of the film is about 0.3 mm and is thin, it can not be
yet said to be sufficient in an actual condition. In the case that
the thickness of the film is set to about 1.0 mm which is a
sufficient thickness for handling, there is generated a problem of
a forming property, or since a thickness of the film coming to a
rigid body in increased in a structure as shown in FIG. 3, a
thickness of a rubber portion is reduced, so that a problem in an
increase of a reaction force is generated, and a fear of a plate
breakage is left. Accordingly, the present invention intends to
solve the problems mentioned above, by forming the cross sectional
shape of the reinforcing body as a two-stage structure as shown in
FIG. 5. Further, since the film is manufactured by molding, it is
possible to achieve an improvement of a yield ratio. In this case,
the rubber material employs the injection molding by applying the
adhesive agent or the adhesive rubber, in the same manner as the
conventional one.
(5) Further, in the item (4) mentioned above, the rubber material
of the gasket employs the injection molding by applying the
adhesive agent or the adhesive rubber, however, in these cases, the
bonding step is necessary in the manufacturing process.
Accordingly, there can be thought that the manufacturing process is
simplified by omitting the bonding step, and the following
structures (6) and (7) are specifically provided.
(6)
(6-1) It is possible to suppress a rubber drop from the frame, by
forming a further multi-step shape, with respect to the stepped
shape frame (the carrier), and the bonding process is not
necessary.
(6-2) It is possible to prevent the rubber drop by forming the
carrier member as a partly convex shape or a partly concave shape,
with respect to a lower surface portion of a rib (a seal lip) which
appears a sealing function, and the bonding process between the
carrier and the rubber is not necessary. A cross sectional shape of
the carrier member itself is no object.
(6-3) A shape of the carrier convex portion or a shape of the
carrier concave portion is formed as a quadrangular cross sectional
shape or a semicircular shape, however, may be formed as the other
shapes than them, for example, a triangular shape or the like.
(6-4) The shape of the carrier convex portion or the shape of the
carrier concave portion may be arranged at plural numbers, and a
further drop preventing effect appears in this case. A plurality of
convex portions or concave portions are arranged from an inner
peripheral side of the gasket toward an outer peripheral side, in a
cross section which is orthogonal to a gasket longitudinal
direction.
(6-5) In the case that there is a fear of an application of an
effect which is not good for a seal function of a rib, by providing
the shape of the carrier convex portion or the shape of the carrier
concave portion in a lower surface portion of the rib, the shape of
the carrier convex portion or the shape of the carrier concave
portion is positioned at a position which is deviated from the rib
on the plane.
(7)
(7-1) It is possible to suppress a rubber drop from the frame and
it is possible to make the bonding process unnecessary, by setting
a through hole to the frame and filling a rubber, with respect to
the stepped shape frame (carrier).
(7-2) It is possible to prevent the rubber drop and it is possible
to make the bonding process between the carrier and the rubber
unnecessary, by setting a through hole to the carrier member
between a rib (a seal lip) which generates the seal function and a
gasket end portion (an outer peripheral portion).
(7-3) It is possible to prevent the rubber drop and it is possible
to make the bonding process between the carrier and the rubber
unnecessary, by setting the through hole to the carrier member
between the rib (the seal lip) which generates the seal function
and a carrier end portion (an inner peripheral portion). In this
case, with respect to the item (7-2) mentioned above, it is
possible to lighten an influence applied to a manifold area due to
a moving deformation of the rubber to the manifold side.
(7-4) It is possible to prevent the rubber drop and it is possible
to make the bonding process between the carrier and the rubber
unnecessary, by setting the through hole to the carrier member in a
lower surface of the rib (the seal lip) which generates the seal
function. In this case, with respect to the items (7-2) and (7-3)
mentioned above, it is possible to lighten the movement of the rib
which is important on the seal function.
(7-5) It is possible to prevent the rubber drop and it is possible
to make the bonding process between the carrier and the rubber
unnecessary, by setting a plurality of through holes to the gasket
and carrier surfaces. In this case, all the effects in the items
(7-2), (7-3) and (7-4) can be generated. A plurality of through
holes are arranged from the inner peripheral side of the gasket
toward the outer peripheral side, in the cross section which is
orthogonal to the gasket longitudinal direction.
(7-6) A shape (an opening shape) of the through hole is not
particularly limited, however, a circular shape is desirable in the
light of a working property.
EMBODIMENTS
Next, a description will be given of embodiments in accordance with
the present invention, however, as a matter of convenience for
description, a description will be first given of a comparative
example. The comparative example is generated in a developing
process of the present invention, and is not a known art. In this
case, in both the embodiments and the comparative example, a gasket
is a gasket for a fuel battery.
Comparative Example
FIG. 1 shows a carrier (a reinforcing body) 11 which is used in a
gasket in accordance with the comparative example as its
constructing part in a single part state, and the carrier 11 is
formed as a planer rectangular shape by using a metal mold (an
injection molding die or the like) while employing a predetermined
resin material as a forming material, and is provided with a space
portion 12 which is going to accommodate a reaction surface in a
fuel battery cell and passes through in a thickness direction, and
a plurality of (four in respective four corners of a rectangular
shape in the drawing) space portions 13 which pass through the cell
in the thickness direction and are going to form a manifold hole,
within the plane.
Further, the carrier 11 is formed so as to be fixed its thickness
t1 (for example, about 3 mm) over a whole surface thereof, and is
formed in one planar shape as a whole of the carrier 11, as shown
in a cross sectional view in FIG. 1B.
If a gasket body 21 which is constructed by a predetermined
rubber-like elastic material is combined with the carrier 11 having
the structure mentioned above, a cross sectional shape thereof
becomes, for example, as shown in FIG. 2. In other words, the
gasket body 21 integrally has an attached portion 22 which is
attached (bonded) to an end portion of the carrier 11 and is formed
as a C-shaped form in a cross section, an extension portion (a seal
lip pedestal portion) 23 which is formed so as to be extended in a
planar direction from the attached portion 22, and seal lips 24
which are provided respectively in both surfaces in the thickness
direction of the extension portion 23 and are formed as a chevron
shape in a cross section, and the seal lip 24 is provided at a
position at which it does not lap over the carrier 11 on a
plane.
Further, as the other example, in an example in FIG. 3, the gasket
body 21 integrally has the attached portion 22 which is attached
(bonded) to the end portion of the carrier 11 and is formed as the
C-shaped form in the cross section, and the seal lips 24 which are
provided respectively in both the surfaces in the thickness
direction of the attached portion 22 and are formed as the chevron
shape in the cross section, and the seal lip 24 is provided at a
position at which it laps over the carrier 11 on the plane.
Further, as the other example, in an example in FIG. 4, the gasket
body 21 integrally has a coated portion 22A which coats the end
portion of the carrier 11 in a non-bonded manner and is formed as a
C-shaped form in a cross section, and the seal lips 24 which are
provided respectively in both surfaces in a thickness direction of
the coated portion 22A and are formed as a chevron shape in a cross
section, and the seal lip 24 is provided at a position at which it
laps over the carrier 11 on a plane. The gasket body 21 and the
carrier 11 are provided with a retaining structure 31 for
preventing both the elements 11 and 21 from coming off from each
other, and the retaining structure 31 is constructed by an
engagement of the gasket body 21 with a three-dimensional shape
formed by convex portions 32 which are respectively provided in
both the surfaces in the thickness direction of the carrier 11.
In this case, in the examples in FIG. 2 and FIG. 3 mentioned above,
the gasket body 21 is formed by injection molding a non-adhesive
rubber after applying an adhesive agent to the carrier 11, or
injection molding an adhesive rubber without applying the adhesive
agent to the carrier 11, however, in the example in FIG. 4, the
gasket body 21 is formed by injection molding the non-adhesive
rubber without applying the adhesive agent to the carrier 11, and
the retaining structure 31 is provided in place of the
adhesion.
In the gaskets from FIG. 2 to FIG. 4, since the carrier 11 is
formed as a product shape from the beginning by using a metal mold
while employing a predetermined resin material as a forming
material as mentioned above, any considerable area part of the
resin film is not cut as is different from the prior art mentioned
above, and it is accordingly possible to improve a yield ratio of
the resin material at this degree.
However, in the gasket in accordance with the comparative example,
the disadvantage still exists in the following points.
In other words, as mentioned above, the carrier 11 is formed so as
to fix the thickness dimension t1 over a whole surface thereof, and
is formed as one planar shape as a whole of the carrier 11.
Accordingly, since a rigidity is low if the thickness t1 of the
carrier 11 is small, it is not possible to solve the problem of the
handling property that a whole of the gasket is sufficiently retain
a shape of the gasket by the carrier 11. Further, if the thickness
t1 of the carrier 11 is set larger for dissolving this problem, the
gasket body 21 is attached to or coated on both the surfaces, and
the thickness as a whole of the gasket is set larger. Therefore, it
is impossible to meet the needs of saving space in the thickness
direction.
Accordingly, in the present invention, a cross sectional shape of
the carrier 11 is set as follows.
First Embodiment
FIG. 5 shows a carrier 11 (a gasket reinforcing body or a gasket
retaining body) 11 which is used in a gasket in accordance with a
first embodiment of the present invention as its constructing part
in a single part state, the carrier 11 is formed as a planer
rectangular shape by using a metal mold (an injection molding die
or the like) while employing a predetermined resin material as a
forming material, and is provided with a space portion 12 which is
going to accommodate a reaction surface in a fuel battery cell and
passes through in a thickness direction, and a plurality of (four
in respective four corners of a rectangular shape in the drawing)
space portions 13 which pass through the cell in the thickness
direction and are going to form a manifold hole, within the
plane.
Further, the carrier 11 is formed as a stepped shape 14 provided
with a step surface 15 which is orthogonal to the plane, by setting
a partial portion which is superposed on a plane with a gasket body
21 (refer to FIG. 6 or FIG. 7) to a thin portion 16 which is
provided with a predetermined thickness t1 (for example, about 3
mm), and setting the other portion which is not superposed on a
plane with the gasket body 21 to a thick portion 17 provided with a
thickness t2 (for example, about 10 mm) which is larger than the
thin portion 16, as shown by a cross sectional view in FIG. 5B. The
partial portion which is superposed on the plane with the gasket
body 21 is specifically a peripheral edge portion of the space
portion 12 which is going to accommodate the reaction surface in
the fuel battery cell, and a peripheral edge portion of a plurality
of space portions 13 which pass through the cell in the thickness
direction and are going to form the manifold hole. The other
portion which is not superposed on the plane with the gasket body
21 is specifically the other portions than the peripheral edge
portion of the space portion 12 which is going to accommodates the
reaction surface in the fuel battery cell, and the other portions
than the peripheral edge portion of a plurality of space portions
13 which pass through the cell in the thickness direction and are
going to form the manifold hole. Further, as a positional
relationship in the thickness direction of the thin portion 16 with
respect to the thick portion 17, the thin portion 16 is arranged in
the center or approximately in the center in the thickness
direction of the thick portion 17. Accordingly, the stepped shape
14 is formed in each of both surfaces in the thickness direction of
the carrier 11.
If a gasket body 21 which is constructed by a predetermined
rubber-like elastic material is combined with the carrier 11 having
the structure mentioned above, a cross sectional shape thereof
becomes, for example, as shown in FIG. 6. In other words, the
gasket body 21 integrally has an attached portion 22 which is
attached (bonded) to an end portion of the carrier 11 and is formed
as a C-shaped form in a cross section, an extension portion (a seal
lip pedestal portion) 23 which is formed so as to be extended in a
planar direction from the attached portion 22, and seal lips 24
which are provided respectively in both surfaces in the thickness
direction of the extension portion 23 and are formed as a chevron
shape in a cross section, and the extension portion 23 and the seal
lips 24 are provided at positions at which they do not lap over the
carrier 11 on a plane. Further, as a positional relationship in the
thickness direction of the extension portion 23 with respect to the
attached portion 22, the extension portion 23 is arranged in the
center or approximately the center in the thickness direction of
the attached portion 22. Further, on the assumption that a
thickness of the attached portion 22 is set to t3, a thickness of
the extension portion 23 is set to t4, and a thickness between
leading ends of both the surface seal lips 24 is set to t5, a
relationship of the thickness is set as follows. t3=t2 (or
t3.apprxeq.t2) t3>t1 t4>t3 t4>t1 t5>t3
Accordingly, an annular concave portion 25 which comes to a
clearance space at a time when the seal lip 24 is compressed in the
case of installing the gasket is provided between the attached
portion 22 and the seal lip 24 which are adjacent to each other on
the plane.
Second Embodiment
Further, as a second embodiment, in an example in FIG. 7, the
gasket body 21 integrally has the attached portion 22 which is
attached (bonded) to the end portion of the carrier 11 and is
formed as a C-shaped form in a cross section, and the seal lips 24
which are provided respectively in both the surfaces in the
thickness direction of the attached portion 22 and are formed as a
chevron shape in the cross section, and the seal lip 24 is provided
at a position at which it laps over the thin portion 16 of the
carrier 11 on a plane. Further, on the assumption that a thickness
of the attached portion 22 is set to t3, and a thickness between
leading ends of both the surface seal lips 24 is set to t5, a
relationship of the thickness is set as follows. t3=t2 (or
t3.apprxeq.t2) t3>t1 t5>t3
In the gasket in accordance with each of the embodiments which are
provided with the structures mentioned above, since the carrier 11
is formed as the planar rectangular shape by using the metal mold
while employing the predetermined resin material as the forming
material, and is formed as the stepped shape 14 by setting the
partial portion which is superposed on the plane with the gasket
body 21 to the thin portion 16, and setting the other portion which
is not superposed on the plane with the gasket body 21 to the thick
portion 17, it is possible to secure a sufficient rigidity by the
thick portion 17 among them, whereby it is possible to further
improve the handling property of the gasket.
Further, since the gasket body 21 is structured such as to be
superposed on the plane with the thin portion 16 not with the thick
portion 17 in the carrier 11, a thickness of a whole of the gasket
is not increased, and it is accordingly possible to secure a space
saving in the gasket thickness direction.
Further, since the carrier 11 is structured such as to be formed by
using the metal mold while employing the predetermined resin
material as the forming material, the carrier 11 is formed as the
product shape from the beginning, and it is accordingly possible to
improve a yield ratio of the resin material.
In this case, in the gaskets in accordance with the first
embodiment (FIG. 6) and the second embodiment (FIG. 7), the gasket
body 21 is formed by injection molding the non-adhesive rubber
after applying the adhesive agent to the carrier 11, or is formed
by injection molding of the adhesive rubber without applying the
adhesive agent to the carrier 11, however, there can be thought
that the manufacturing of the gasket is made easier by omitting the
bonding step from the manufacturing process. In this case, the
gasket body 21 is formed by injection molding of the non-adhesive
rubber without applying the adhesive agent to the carrier 11, and
the retaining structure for preventing both the elements 11 and 21
from coming off from each other is provided in the gasket body 21
and the carrier 11, in place of the adhesion. The retaining
structure is constructed by providing an engagement portion which
is constructed by a three-dimensional shape such as a convex
portion, a concave portion, a through hole or the like in the
carrier 11, and engaging the gasket body 21 with respect to the
engagement portion. A description will be given below of an
embodiment of a non-adhesion type.
Third Embodiment
FIG. 8 shows an entire plane of a gasket in accordance with a third
embodiment of the present invention. In this gasket, the carrier 11
is formed as a planar rectangular shape by using a metal mold (an
injection molding die or the like) while employing a predetermined
resin material as a forming material, and is provided with the
space portion 12 which is going to accommodate the reaction surface
in the fuel battery cell and passes through in the thickness
direction, and a plurality of (three in each of both ends in a
longitudinal direction of the rectangle in the drawing) space
portions 13 which pass through the cell in the thickness direction
and are going to form the manifold hole, within the plane.
Further, the carrier 11 is formed as the stepped shape 14 provided
with the step surface 15 which is orthogonal to the plane, by
setting a partial portion which is superposed on a plane with the
gasket body 21 to the thin portion 16 which is provided with the
predetermined thickness t1 (for example, about 3 mm), and setting
the other portion which is not superposed on a plane with the
gasket body 21 to the thick portion 17 provided with the thickness
t2 (for example, about 10 mm) which is larger than the thin portion
16, as shown by a cross sectional view in FIG. 9. The partial
portion which is superposed on the plane with the gasket body 21 is
specifically the peripheral edge portion of the space portion 12
which is going to accommodate the reaction surface in the fuel
battery cell, and the peripheral edge portion of a plurality of
space portions 13 which pass through the cell in the thickness
direction and are going to form the manifold hole. The other
portion which is not superposed on the plane with the gasket body
21 is specifically the other portions than the peripheral edge
portion of the space portion 12 which is going to accommodates the
reaction surface in the fuel battery cell, and the other portions
than the peripheral edge portion of a plurality of space portions
13 which pass through the cell in the thickness direction and are
going to form the manifold hole. Further, as a positional
relationship in the thickness direction of the thin portion 16 with
respect to the thick portion 17, the thin portion 16 is arranged in
the center or approximately in the center in the thickness
direction of the thick portion 17. Accordingly, the stepped shape
14 is formed in each of both surfaces in the thickness direction of
the carrier 11.
If the gasket body 21 which is constructed by the predetermined
rubber-like elastic material is combined with the carrier 11 having
the structure mentioned above, a cross sectional shape thereof
becomes, for example, as shown in FIG. 9. In other words, the
gasket body 21 integrally has a coated portion 22A which is coated
with the end portion of the carrier 11 in a non-bonded manner and
is formed as a C-shaped form in a cross section, and the seal lips
24 which are provided respectively in both surfaces in the
thickness direction of the coated portion 22A and are formed as a
chevron shape in a cross section, and the seal lips 24 are provided
at positions at which they lap over the thin portion 16 of the
carrier 11 on a plane. Further, on the assumption that a thickness
of the coated portion 22A is set to t3, and a thickness of between
the leading ends of both the surface seal lips 24 is set to t5, a
relationship of the thickness is set as follows. t3=t2 (or
t3.apprxeq.t2) t3>t1 t5>t3
Further, since there is a fear that the gasket body 21 easily comes
off from the carrier 11 if the gasket body 21 is assembled in the
non-bonded manner with respect to the carrier 11, the gasket body
21 and the carrier 11 are provided with the retaining structure 31
for preventing both the elements 11 and 21 from coming off from
each other, and the retaining structure 31 is structured
specifically as follows.
In other words, in the third embodiment (FIG. 9), the
three-dimensional shape which is constructed by the convex portion
32 is provided in each of both the surfaces in the thickness
direction of the thin portion 16 in the carrier 11, and the convex
portion 32 is structured such as to be embedded within the coated
portion 22A of the gasket body 21 in accordance with an injection
molding of the gasket body 21, and the gasket body 21 engages in a
coming off direction (a rightward direction in the drawing) with
respect to the convex portion 32, thereby constructing the
retaining structure 31.
As the retaining structure 31, a shape and a structure thereof are
not particularly limited as long as it can prevent both the
elements 11 and 21 from coming off from each other, however, it may
be additionally structured, for example, as follows.
Fourth Embodiment
In a fourth embodiment shown in FIG. 10, a three-dimensional shape
which is constructed by a concave portion 33 is provided in each of
both the surfaces in the thickness direction of the thin portion 16
in the carrier 11, and the concave portion 33 is structured such
that a partial rubber material of the gasket body 21 is filled in
accordance with an injection molding of the gasket body 21, and the
gasket body 21 engages in a coming off direction (a rightward
direction in the drawing) with respect to the concave portion 33,
thereby constructing the retaining structure 31.
Fifth Embodiment
In the third embodiment (FIG. 9) and the fourth embodiment (FIG.
10), the cross sectional shapes of the convex portion 32 and the
concave portion 33 are formed as a quadrangular shape, however,
they may be formed as a semicircular shape or a triangular shape
without being limited to this. In a fifth embodiment shown in FIG.
11, the cross sectional shape of the concave portion 32 is formed
as a semicircular shape.
Sixth Embodiment
In the third embodiment (FIG. 9) and the fourth embodiment (FIG.
10), the convex portion 32 and the concave portion 33 are provided
at the position which is superposed on the plane with the seal lip
24 in the gasket body 21, however, may be provided at a position
which is not superposed on the plane with the seal lip 24 and is
closer to the leading end of the thin portion 16, without being
limited to this. In a sixth embodiment shown in FIG. 12, the convex
portion 32 is provided at a position (a leading edge position)
which is not superposed on the plane with the seal lip 24 and is
close to the leading end of the thin portion 16.
Seventh Embodiment
In the third embodiment (FIG. 9) and the fourth embodiment (FIG.
10), the convex portion 32 and the concave portion 33 are provided
at the position which is superposed on the plane with the seal lip
24 in the gasket body 21, however, may be provided at a position (a
position between the seal lip 24 and the thick portion 17) which is
not superposed on the plane with the seal lip 24 and is closer to a
base end of the thin portion 16. In a seventh embodiment shown in
FIG. 13, the convex portion 32 is provided at a position which is
not superposed on the plane with the seal lip 24 and is closer to
the base end of the thin portion 16.
Eighth Embodiment
In the third embodiment (FIG. 9) and the fourth embodiment (FIG.
10), the convex portion 32 and the concave portion 33 are provided
at one by one (one position) in each of both the surfaces in the
thickness direction of the thin portion 16 in the carrier 11,
however, may be provided at a plurality of positions without being
limited to this. In an eighth embodiment shown in FIG. 14, the
convex portions 32 are provided at a plurality of positions (five
by five (five positions) in the drawing) over the position which is
superposed on the plane with the seal lip 24, the position which is
not superposed on the plane with the seal lip 24 and is closer to
the leading end of the thin portion 16 and the position which is
not superposed on the plane with the seal lip 24 and is closer to
the base end of the thin portion 16.
Ninth Embodiment
In a ninth embodiment shown in FIG. 15, a three-dimensional shape
which is constructed by a through hole 34 passing through in the
thickness direction is provided in the thin portion 16 in the
carrier 11, and the through hole 34 is structured such that a
partial rubber material of the gasket body 21 is filled in
accordance with an injection molding of the gasket body 21, and the
gasket body 21 engages in a coming off direction (a rightward
direction in the drawing) with respect to the through hole 34,
thereby constructing the retaining structure 31. A lot of through
holes 34 are provided at a predetermined distance along a gasket
longitudinal direction (a direction which is orthogonal to a paper
surface in the drawing).
Tenth Embodiment
In the ninth embodiment (FIG. 15) mentioned above, the through hole
34 is provided at the position which is superposed on the plane
with the seal lip 24 in the gasket body 21, however, may be
provided at a position which is not superposed on the plane with
the seal lip 24 and is closer to the leading end of the thin
portion 16, without being limited to this. In a tenth embodiment
shown in FIG. 16, the through hole 34 is provided at a position
which is not superposed on the plane with the seal lip 24 and is
closer to the leading end of the thin portion 16.
Eleventh Embodiment
In the ninth embodiment (FIG. 15) mentioned above, the through hole
34 is provided at the position which is superposed on the plane
with the seal lip 24 in the gasket body 21, however, may be
provided at a position which is not superposed on the plane with
the seal lip 24 and is closer to the base end of the thin portion
16, without being limited to this. In an eleventh embodiment shown
in FIG. 17, the through hole 34 is provided at a position which is
not superposed on the plane with the seal lip 24 and is closer to
the base end of the thin portion 16.
Twelfth Embodiment
In the ninth embodiment (FIG. 15) mentioned above, the through hole
34 is provided one by one (at one position) in a cross section
which is orthogonal to the gasket longitudinal direction, however,
may be provided at a plurality of positions without being limited
to this. In a twelfth embodiment shown in FIG. 18, the through
holes 34 are provided at a plurality of positions (five positions
in the drawing) over the position which is superposed on the plane
with the seal lip 24, the position which is not superposed on the
plane with the seal lip 24 and is closer to the leading end of the
thin portion 16, and the position which is not superposed on the
plane with the seal lip 24 and is closer to the base end of the
thin portion 16.
In this case, in each of the embodiments mentioned above, the
convex portion 32 and the concave portion 33 are provided like a
continuous linear shape which extends along the gasket longitudinal
direction, however, a lot of them may be provided at a
predetermined distance along the gasket longitudinal direction such
as the through holes 34.
Further, in each of the embodiments mentioned above, the convex
portion 32 and the concave portion 33 are provided in each of both
the surfaces in the thickness direction of the thin portion 16 in
the carrier 11, however, may be provided in only one surface.
Further, in each of the embodiments mentioned above, a whole
structure of the gasket is set to the type in FIG. 7 (the type that
the gasket body 21 has the attached portion 22 (the coated portion
22A) and the seal lip 24, and the seal lip 24 is provided at the
position which is superposed on the plane with the thin portion 16
of the carrier 11), however, may be set to the type in FIG. 6 (the
type that the gasket body 21 has the attached portion 22 (the
coated portion 22A), the extension portion 23 and the seal lip 24,
and the seal lip 24 is provided at the position which is not
superposed on the plane with the thin portion 16 of the carrier
11), and the gasket of the type in FIG. 6 may be formed as the
non-bonded structure as described in each of the embodiments.
* * * * *